A vtron Course Objectives

Explain the purpose of the A vtron systemsused on shovels and drills.

II. Identify all the major components utilized on the A vtron system for shovels and
drills.

Ill. Explain the purpose of all the major componentsutilized on the A vtron system for
shovels and drills.

Identify and predict all safety issues with the A vtron syst~m.

Vo Identify the operatingprinciplesemployedin the A vtron control methodology.

VI. Be proficient in loading, configuring, usage,and application of software programs

required for the A vtron system.

Analyze schematicsand control diagrams utilized on the shovels and drills as it

relates to the A vtron system for troubleshooting and repair.

Removeandreplacefaulty componentsincluding a failure analysis.

IX. Modify A vtron systemin accordancewith engineeringdocuments/procedures.

x. Performoperationalchecks/alignment
proceduresfor the A vtron system.

XI. Compose a FSR detailing all required items for a give,nscenario.

I.
 A vtron Digital Drive Course Layout

I. Introduction
A. Safety
B. Material Sources
C. Electrotorque Plus Block Diagram
ll. Advanced Firing Module (AFM) Component Layout
A. Shovels
1. Control Cabinet Layout
2. Front Panel
3. Microprocessor Board
4. Systems Interface(Maxi) Board
5. Bridge Interface Board
6. FAX32 Board
B. Drills
1. Converter Cabinet Layout
a. Front Cabinet View
b. Second Level View
2. Front Panel
3. Microprocessor Board
4. SystemsInterface Board
5. Bridge Interface Board
6. Field Assembly
7. Armature Assembly
DI. Control System Overview
A. Digital Building Blocks
B. Data Types
C. Shovels
1. HoistlPropel
2. Swing
3. Crowd/Propel
4. Fields
5. RPC
D. Drills
1. HoistIPulldown
2. Rotary
IV Software Programs
A. FlashZap
B. ADDapt
Maintenance
A. Troubleshooting
B. AssemblylDisassembly
C. Preventive
VI. Appendix
 Safety (1)

Impact of Safety

.Personnel

.Equipment

.Production

2. Warnings Provided in Reference Material

An operating or maintenance procedure, practice,

etc., which if not correctly followed WILL result
in SEVERE personal injury, death, or substantial
property damage.

An operating or maintenance procedure, practice,

etc., which if not correctly followed CAN result in
SEVERE personal injury, death, or substantial
property damage.

An operating or maintenance procedure, practice,

etc., which if not correctly followed WILL or CAN
cause personal injury or property damage.

NOTICE

Hornischfeger Institute P&H

1.1.3

c.
1.
 CAUTION

certain circuit card assemblies and their

components, typically integrated circuits, may
be damaged by seemingly undetectable
electrostatic discharge (ESD). Care must be
exercised during handling/repair of these
items. Use electrostatic discharge
precautionary procedures.

The following guidelines are not necessarily all inclusive but

'. rather serve as reminders for good shop practices for the handling/
repair of ESD sensitive circuit card assemblies and devices.
store ESD sensitive items in their original containers.
These items are often marked with this s~ol f;1.

Put on a grounded wrist strap before handling any ESD

sensitive item.
Clear work area of styrofoamR* plastic, and vinyl items
such as coffee cups.
Handle ESD items by the body, the open edge
connectors.
Never slide ESD sensitive items over any surface.

Transport ESD sensitive items in a static shielding

container to a static-free work station.
If a static-free work station is not available, ground
the transport container before removing or inserting an
ESD item.
E1ectric tools used during repair should be grounded.
For example, use only anti-static type solder suckers and
grounded tip soldering irons. Discharge non-electric
tools before use.
Pack ESD items in static shielding containers before
shipping them to Avtron for repair.

.styrofoamR is a registered trademark of Dow Chemical.

lO/16f)O ~/)~\Y!!!.2~

,
neve!:
 Application Notes

Introduction Electrostaticdamage(ESD)is a major causeof failures andmalfunctions

in today'ssophisticatedelectrical componentS
and systems.
Somemanufacturesof electronicsystemsmay tell you that ESDis not a
problemwith their productS.This is misleading.All conscientious
manufacturestake anti-staticprecautionswhenthey designtheirproduCtS.
However,eventhe bestanti-staticdesignscannotkeepESDfrom affecting
sophisticatedelectronicsystems,particularlywhentheyaredisassembled.
Propereducationcombinedwith work-relatedproceduresandprecautions
canguardagainstmanyof the effectSofESD. This documentexplainsthe
causesof ESD, and how youcan guardagainstits effects.

What'sin this Document This documentcontains:

Harnischfeger Institute P&H Mining Equipment

1.2.1
A.
 Electrostatic-Safe Practices (2)

Wearinga WristStrap
The mostimportantaspectof guardingagainstESDis wearing a wrist
strapthat connectsyou to a groundin a static-safework area. A wrist strap
usuallyconsistsof:
.elastic wrist strapwith snapfastener
.molded groundedlead with snapandbananaplug -has a built-in 1
Mohm resistorin seriesto guardagainsthazardous
electric shockcaused
by accidentalcontactwith line voltage
.alligator clip -for connectionwith the groundlead and with ground

Ground lead

,I

Elastic Wrist Strap

AlligatorClip

BananaPlug

14877

You shouldalwayswearandusea wriSt strapin nonnal work activities

aroundsensitivecomponentS:
.put the ~"1 strapon beforebeginningworlc
.make surethe v.'riststrapfits snugly
.make surethe groundlead of the wrist strapis assembledproperly and
connectedsecurelyto groundeachtime youuseit
.take off thewrist strapasthe last thing you do before leaving the work
area

Harnischfeger Institutp P&H Mining Equipment

1.2.3
B.
 c. Electrostatic Sensivity and Damage Effects

Sensitivityof Many electroniccomponents aresensitiveto electrostaticvoltagesas low

Componentsto ESD as 30 volts and currentaslow as0.001amps,far lessthan you canfeel,
hear, or see.

Hidden Effects of
ElectrostaticDamage
ESD immediately destroys sensitive devices in only 10% ofmostESD
incidents. It degradesperformance in the remaining 900/0..Only a quaner
of the voltage required to destroythe component is neededto degrade its
perfonnance.
A device that is merelydegradedin performancemaypassall normal
diagnostic tests.However,it mayfail intermittentlyastemperature,
vibration, andload onthe devicevary. lntimately, the devicemayfail
prematurely: days,weeks,or evenmonthsafterthe ESD incidentthat
degradedit.
If you have someminimal Staticcontrolprocedures,you may only
experiencea devicefailurerate of 0.5%. But, if thereare:
.10 devicesperboard= 5% defectiveboards
.10 boardsper system= 40%defectivesystems
This points outthe needto follow rigorousStaticconttolproceduresat all
times when handlingandworking with static-sensitivedevicesand
modules.

Harnischfeger Institut" P&H Mining Equipment

1.2.5
 B. Electrostatic-Safe Practices (1)

PracticesthatGuard To guard againstelecuostaticdamage,youcan:

AgainstESD .create a static-safework area
.handle sensitivecomponentsCOITectly
.wear a wrist strapthat groundsyou duringwork

A ATTENllON: To avoid shockor personalinjury from

~ accidentalcon~ct wi~ line v.oltage,the g;r~undlead of the wrist
sn-apmustprovIdea highresIstance,a mlrumumof 1 Mohm,
pathto ground.

Creating a Static-safe Work Area

An imponant aspectof guardingagainstESDis creatinga static-safework
area.To createa static-safework area:
.cover a work benchwith a conductivesurfacethat is grounded
.cover the floor of the work areawith a conductivematerial thatis
grounded
.remove nonconductivematerialsfrom the worlcareasuchas:
.plastics
.nylon
.styrofoam
.cellophane
.ground yourself by touching a conductivesurfacebeforehandling
static-sensitivecomponents
.be carefulwith loose parts of clothingsuchassleeves,ties, andscarfs,
which can easilycarry a charge
.be carefulnot to touch the backplaneconnectoror COIU1ector
pins of the
system
be carefulnot to touch othercircuit componentsin a module when you
configure or replaceinternal componentsin a module

Harnischfeger Institutp P&H Mining Equipment

1.2.2
 Electrostatic-Safe Practices (3)

HandlingSensitiveComponentsCorrectly
The last imponant aspectof guarding againstESDis to alwaysstore and
carry componentsandmodules in static-shieldingcontainersthat guard
againstthe effect of electric fields.
Remove componentS andmodules from static-shieldingpackagesonly ata
static-safeWOr'lC
area.Modules are only protectedwhenthey are
completelyin a static-shieldingbag. Usingthe bagto hold the module does
not protectthe module.
You shoulduse correcthandling proceduresevenwith modulesthat are
being returnedfor repair.This protectsthe good componentSfor rework.

Common Electrostatic You needto build up only 3,500 volts to feel the effectsofESD, only
Voltages at Work 4,500 volts to hearthem,and only 5,(XX)voltsto seea spark.The noln1al
movementsof someonearound a work benchcan generateup to 6,(XX)
volts. The chargethat builds up on someonewho walks acrossa nylon
carpetin dry air canreach35,000 volts. Potentialsashigh as 56,000volts
have beenmeasuredwhena roll of plain polyethyleneis unwound.
Potentialsin more common work situationsrangeup to 18,000volts.

A Can generatethis voltage

Personwalkingon carpeton a
.humid day '2,000
.dry day 35,000
--~

Person walking on vinyl flooron a

.humid day 400

i
.dry day
- 112,000
Personin paddedchair
Styrofoam
coffeecup
Plasticsoldersipper
Vinyl coverednotebook

Harnischfeger Institut'" -P&H Mining Equipment

1.2.4
B.
 Causes of Electrostatic Damage (1)

Causesof Elecn-ostaticdamageis causedby theeffectsof an electric field that

Electrostatic Damage
.discharge -the chargeassociatedwith the field is suddenlygrounded
surroundsall chargedobjectS.The electricfield can damagesensitive
componen~
by:
andthe movementof the chargecreatescurrentsin the device.
.induction -the electricfield movesin relation to the deviceand
generatesa currentin the de\ice.
.polarization -the electricfield remainsstationaryandpolarizesthe
device. Subsequent
handlingand groundingfirst chargesthendischarges
the device.
Electric fields areinvisible, and existaroundall chargedmaterials.They
cangeneratecurrentsin conductorssimply by moving nearthem.The size
of the currentdependsonthe sn-engthof the field andthe speedof
movement.Electric fields can polarizesensitivedevices.Subsequent
handlingcan causechargingand dischargingof the device.

DamageDue to Discharge
The surfacesof nonconductivematerialsdevelopequaland opposite
chargeswhen theycomein contact,move againsteachother,then separate
quickly. An electric field surroundsa nonconductivematerialonce it is
charged.
We normally developchargein our bodiesandclothing aswe move.
Whenwe walk on a ~t, our feet rub on thenseparatefrom the CaIpet.
whichcan give us a chargevery quickly.
Whenwe approacha conductor,like a door knob or one of today's
sensitiveelectronicdevices,the air betweenour body andthe conductor
initially aCtSas aninsulator. At somepoint, the amountof chargewe have
built up exceedsthe insulating ability of the air, and a spaIkjUJ.'"DpS
to the
conductor.

1~78

The sparkintroducescurrentsin the conductor: Thesecun-entscould

destroya sensitivedeviceor degradeperformance.

Harnischfeger Institutp P&H Mining Equipment

1.2.6

D.
 DamageDueto Induction
A conductorthat moves in a magneticfield generatesan electriccurrent.
This is the basic principle of a generator:induction. The principleis the
sameif the magIletic field movesandthe conductoris atrest. Theelectric
field is similar to the magneticfield in its ability to generatea cunent.
Walling acrossa carpet,building up charge,and approachinga sensitive
devicecausesyour electricfield to moveacrossthe conductorsof the
device. The strongeryour electricfield, andthe faster your approach,
the
more likely you are to inducedamagingcurrents.

14879

DamageDue to Polarization
If the electric field and a sensitivedeviceremainstationary,butcloseto
eachother, a polarization effect mayoccur.
A goodexample of polarizationis a styrofoamcoffee cupplacednextto a
chip. The cup is a nonconductorthat is easilychargedby handling,or even
simple movementin the air. Polarizationcausesthe electronsonthechip,
which are negative, to beattractedto the cup,which is positivelycharged.
At this point, the chip is not charged.It is polarized.

Harnischfeger Institut~--- P&H Mining Equipment

1.2.7
 Electrotorque Control

Armature Converter

Armature Control

Field Converter

Field Control

Harnischfeger Institute 780A Page i-2

 Introductionand GeneralInConnation ADDvanlage-32
AC to DC Power Converter

1.4 mENTMCATION OF PART NUMBERS

RARDWARE PART NUM~EB (EXAMPLE)

QUAD-
MODEL TYPE SYSTEM 1.0. AND RANTS/ SYSTEM OPTION OPTION
ALWAYS DC AMP RATING AfM BOARD 1 2
FIELD

D c 0 0 3 0 4 A 0 0

~OFTWARE PART NUMBER (EXAMPLE)

VERSION NUMBER

v 2 5

FIGURE1-18. PART NUMBER BREAKDOWN

JRS/ky
4/17/95,Rev. 7/24/96
1-27
Communication Panel

+5VPOWERON
RUNNING
EMERGSTOPOK
DRNEREADY

USERLED
CURRENTUMrr
FWD BRIDGE ON
REV BRIDGE ON
DRNEFAULT
FIELD WSS
IOCFAULT
PROCESSORFAIL

(AI EJ
(!] [[)

DESCRIPTION

m I

(AI EJ
[!] [§]
 Keypad Functions

The up arrow key moves up through the loop of options in the MENUS,
SUBMENUS and PARAMETERS.

The down arrow key moves down through the loop of options in the MENUS,
SUBMENUS and PARAMETERS.

The right arrow key moves from MENUS to SUBMENUS to PARAMETERS.

L--J

The liS" key (S = Select) moves from PARAMETER to SUBMENU to MENU.

Display

The LCD Display has two rows of sixteen alphanumeric characters. When
the ADD -32 is powered up, the display flashes a solid bar, " Avtron
Advantage -32", followed by the first menu choice, IIOPERATE ".
To loop through the menu selections, press either the up or down arrows.

Hamischfeger Institute
650
 i95O
EB'RON

BAa< OF LEOS

BACK OF KEVPAD
AND OOA.A Y

FIGURE1-5. MICROPROCESSOR
BOARD (Al)
 yr.;::
~ /
/
/
REMOVABLE HINGES
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fj
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J4
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'
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J1[
J5
J3
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'- /~ CASE
MOUNTING SCREW
MICF SSOR
(A1)
BASE
\~ ~
'/.I.'
).,r
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 Converter Cabinet
Front Panel

[=:J

'"
"\.
"
""

Harnischfeger P&H
Institute 650
5.1

'\
Converter Cabin
Rear Panel
 Communication Panel

+5 V POWERON
RUNNING
EMERG.STOPOK
DRIVE READY

USERLED
CURRENTUMlT
FWD BRIDGE ON
REV BRIDGE ONI
DRIVEFAULT
FIELD WSS
IOCFAULT
PROCESSORFAIL

I I [i) 8
I!] I[]

DESCRIPTION

~ I

I I (!]
I!I

~
 ADDvanbgc-32
Control Block Description AC to DC Power Converter

4.3 4 ANALOG SELECT

This block is used to select one of four possible a~alog

signal paths. It can be used to control the application of
multiple reference signals to a single input point.

INPB

INPC

FIGURE4-3. 4 ANALOG SELECT BLOCK

1 InQuts
Analog
Analog
Analog
Analog
Bit
Bit

OutQut
OUT: Analog

TRW/kv
4/17/95
4-3

2.
INPA:INPB:INPC:INPD:
CNTL1:CNTL2:
 ADDvanlage-32
Control Block Description AC 10 DC Power Converter

4.5 5 SUMMER

The 5 Summer block selectively sums up to five analog input

signals. The selection of which inputs are to be summed is
set using a series of digital bits.

FIGURE 4-5. FIVE SUMMER BLOCK

InQuts
Ana
Ana
Ana
INPD: Ana
INPE:BIT1: Ana
Bit
BIT2: Bit
BIT3: Bit
BIT4: Bit
BIT5: Bit

out~ut
OUT: Analog

TRW/k.v
4/17/95
4-6

1.
2.
INPA:INPB:INPC:
logloglogloglog
 ~I , ~
"

:J ! '. ;
W I -¥'-"
~7 .-'
0
Z

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~ w
= j ~
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I- -II ~- I

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W ou
5 01- .-
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11) -'W 0
~ -'W 0.-
~I '" og <
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t" ~~ 101
0 -'
-'-, ~
~UJ -' 0
01
.:; 1 ~ ~ --~ <'"
~ m ~
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811 ! g

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I~~ ,§ I
z
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~I- : I, 01-
<-'
-'M ;1 <-'
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0(
ZW ZUJ W
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a:
liJ 0:0- m 0(
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m-
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Z !' I-z
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I
~ ~ 00
UJ~ ~
Q.w I-

~J I-~
~a
I-'Z
~
~
(J)W

FIGURE4-21. CURRENT LIMIT BLOCK DIAGRAM

TRW/kv
4/17/95
4-33

~
~
~
 ADDvantage-32
Control Block Description AC to DC Power Converter

:4.45 PROPORTIONAL AND INTEGRAL CONTROL (PI)

The PI block performs a proportional ang iQt~q~al gain

function on an error signal. It has- inputs
, '£or- maximum
-- and
minimum limits which prevent the loop from oyercompensating.

MAX

OUT

MIN

FIGURE 4-45. PI BLOCK

InQuts Data Type DescriDtion

Analog Input Signal

Analog Proportional Gain Value
I:MAXL:MINL:Analog Integral Gain Value
Analog output High Limit Value
Analog Output Low Limit Value
PREL: Analog Integrator Preload Value
HOLD: Bit Integrator Hold Enable
PRE: Bit Integrator Preload Enable

TRW/kv
4/17/95
4-63

1.
ERR:P:
 APPLICATION
SOFTWARE

FIGURE2-3. PARAMETER LAYOUT

TABLE2-1. PARAMETER ORGANIZATION

PARAMETER PJ...RAMETER
GROUP TYPE DESCRIPTION
x*** Calibration X*** parameters are part of the
core software. Core parameters
perform tasks specific to the
ADDvantage-32 hardware being used.
y*** Configuration y*** parameters are also part of
the core software. These
parameters set up the functionality
of the ADDvantage-32 hardware.
c*** Calibration c*** parameters are specific to the
application block software being
used. Many of these parameters are
permanently fixed to specific
blocks. Others can ~e configured
using p*** parameters.

Hamischfeger Institute P&H

 TABLE 2-1. PARAMETER ORGANIZATION (Cont.)

PARAMETER PARJI.METER
GROUP .TYPE DESCRIPTION
p*** Configuration p*** parameters are also ~pecific
to the type of application block
software used with theADDvantage-32.
p*** parameters
link specific blocks together, or
configure a c*** parameter to
another block.
A*** Analog Data A*** parameters are read-only
parameters. They represent all the
information in the analog data
table. p*** and y*** parameters
can map this information into the
block software.
D*** Digital Data D*** parameters are also read-only.
They represent all the values in
the digital. data table. A D***
parameter has a value of either one
or zero. A one Uleans the condition
is true. These values can also be
mapped using the p*** and y***
parameters.
T*** Calibration T*** parameters are table entry
values for the ADDvahtage-32
tables. (Defined as X,Y points)
z*** Calibration Z*** parameters are a mix of
and configurable and calibratable
Configuration values for the four built-in signal
analyzers.
Q*** Data Value Q*** values are read-only
parameters used by the y*** and
Z*** parameters. They represent
selections available for certain
parameters.
R*** LAN Auto Scan R*** parameters configure the
information to be accessed over the
802.4 LAN.

Hamisch.feger Institute P&H

5_3.7